Basics of Injection Molding

Nov 08 2010 01:30 PM | Chris Haslego

in Bulk Solids

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Making polymers is a fantastic science. Then there is the matter of shaping the plastic into useful
objects....another fantastic science. One of the most common methods of shaping plastic resins is a
process called injection molding. Injection molding is accomplished by large machines called injection
molding machines.
Resin is fed to the machine through the hopper. Colorants are usually fed to the machine directly
after the hopper. The resins enter the injection barrel by gravity though the feed throat. Upon
entrance into the barrel, the resin is heated to the appropriate melting temperature.

The resin is injected into the mold by a reciprocating screw or a ram

injector. The reciprocating screw apparatus is shown above. The
reciprocating screw offers the advantage of being able to inject a smaller
percentage of the total shot (amount of melted resin in the barrel). The ram
injector must typically inject at least 20% of the total shot while a screw
injector can inject as little as 5% of the total shot. Essentially, the screw
injector is better suited for producing smaller parts.

Figure 1: Diagram of
Injection Molding Machine

Figure 2: Photo of Injection

Molding Machine

Figure 3: Diagram of
Heated Screw Conveyor

The mold is the part of the machine that receives the plastic and shapes it
appropriately. The mold is cooled constantly to a temperature that allows
the resin to solidify and be cool to the touch. The mold plates are held
together by hydraulic or mechanical force. The clamping force is defined as
the injection pressure multiplied by the total cavity projected area. Typically
molds are overdesigned depending on the resin to be used. Each resin has
a calculated shrinkage value associated with in.

Some Typical Complications

Burned or Scorched Parts: Melt temperature may be too high. Polymer may be becoming trapped
and degrading in the injection nozzle. Cycle time may be too long allowing the resin to overheat.
Warpage of Parts: Uneven surface temperature of the molds. Non-uniform wall thickness of mold
design.
Surface Imperfections: Melt temperature may be too high causing resin decomposition and gas
evolution (bubbles). Excessive moisture in the resin. Low pressure causing incomplete filling of
mold.
Incomplete Cavity Filling: Injection stroke may be too small for mold (ie. not enough resin is being
injected). Injection speed may be too slow causing freezing before mold is filled.

Diagrams courtesy of Plastics: Materials and Processing, Prentice Hall by A. Brent Strong